Operator input device for a robotic surgical system

ABSTRACT

A device for receiving data from a rotatable source includes a primary winding of a rotary transformer fixed to a support structure and connected to an electric power source. A secondary winding is rotatably supported by the support structure. An axial passage extends through the primary and secondary windings. An optical data transmitter is connected to the secondary winding. The optical data transmitter is rotatably supported by the support structure and aligned to transmit data through the axial passage in the rotary transformer. The secondary transformer winding provides power to the optical data transmitter without physical contact. An optical data receiver fixed to the support structure receives data from the optical data transmitter transmitted through the axial passage in the rotary transformer without physical contact. The transmission of power and data without physical contact allows the data source to rotate continuously.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 12/242,275,filed Sep. 30, 2008, which is hereby incorporated by reference in itsentirety.

BACKGROUND

1. Field

This invention relates to data input devices, and more particularly,provides a master controller which may be used for directing movementsof a robot and which is particularly useful for robotically enhancedsurgery.

2. Background

In robotically assisted surgery, the surgeon typically operates a mastercontroller to remotely control the motion of surgical instruments at thesurgical site. The controller may be separated from the patient by asignificant distance (e.g., across the operating room, in a differentroom, or in a completely different building than the patient).Alternatively, a controller may be positioned quite near the patient inthe operating room. Regardless, the controller will typically includeone or more hand input devices.

These hand input devices are coupled by a servo mechanism to thesurgical instrument. More specifically, servo motors move a manipulatoror “slave” supporting the surgical instrument based on the surgeon'smanipulation of the hand input devices. During an operation, thecontroller may employ, via the robotic surgery system, a variety ofsurgical instruments such as tissue graspers, needle drivers,electrosurgical cautery probes, etc. Each of these structures performsfunctions for the surgeon, for example, holding or driving a needle,grasping a blood vessel, or dissecting, cauterizing, or coagulatingtissue.

To deliver the full potential of this new form of surgery, the roboticsystem will preferably allow movement of the end-effector in bothposition and orientation. Directing such robotic input is much easierwhen the surgeon is able to move the hand input device with motions thatcorrespond to the desired motions of the end-effector. Hence, it wouldbe desirable to provide hand input devices which can move inthree-dimensional space, and which can also change in orientation aboutthree axes.

In particular, the ability to control a twisting motion (roll) with thefingers about one of the axes is an important motion. A rotatable handlemay be used by the operator to control twisting motions of a surgicalinstrument. Further, it is desirable to provide additional operatorinputs, such as switches to actuate a surgical instrument, such as acautery probe, and grip controls to open and close a surgical instrumentsuch as forceps or scissors. These additional operator and grip controlsmay be placed on the rotatable handle.

The placement of operator inputs on the rotatable handle requires thatthe input from the controls be transmitted through a rotating joint.Slip rings may be used to transmit the data, but slip rings aredifficult to maintain and may introduce noise into the data signals,which could have undesirable consequences in the context of a roboticsurgery. A slack wire cable provides reliable data communication butlimits the rotational freedom of the handle, which adds an undesirablelimitation on the freedom of the surgeon to direct the surgicalinstrument. Further, any operator input device needs to be compact andrelatively light weight to increase the device's agility and minimizeits constraints on the surgeon's ability to manipulate the surgicalinstrument.

In light of the above, it would be desirable to provide an improvedoperator input device for a robotic surgical apparatus.

SUMMARY

A device for receiving data from a rotatable source includes a primarywinding of a rotary transformer fixed to a support structure andconnected to an electric power source. A secondary winding is rotatablysupported by the support structure. An axial passage extends through theprimary and secondary windings. An optical data transmitter is connectedto the secondary winding. The optical data transmitter is rotatablysupported by the support structure and aligned to transmit data throughthe axial passage in the rotary transformer. The secondary transformerwinding provides power to the optical data transmitter without physicalcontact. An optical data receiver fixed to the support structurereceives data from the optical data transmitter transmitted through theaxial passage in the rotary transformer without physical contact. Thetransmission of power and data without physical contact allows the datasource to rotate continuously. An embodiment of the device may be usedas an input device for a robotic surgical instrument that includes anoperator input on a handle that is rotatably supported by the supportstructure.

Other features and advantages of the present invention will be apparentfrom the accompanying drawings and from the detailed description thatfollows below.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may best be understood by referring to the followingdescription and accompanying drawings that are used to illustrateembodiments of the invention by way of example and not limitation. Inthe drawings, in which like reference numerals indicate similarelements:

FIG. 1 is a perspective view of a master control workstation and amanipulator system for robotically moving a plurality of minimallyinvasive surgical instruments.

FIG. 2 is another perspective view of the master control workstationshown in FIG. 1.

FIG. 3 is a perspective view of an operator input device used in themaster control workstation shown in FIG. 2.

FIG. 4 is another perspective view of the operator input device shown inFIG. 3.

FIG. 5 is a cut-away view of the operator input device shown in FIG. 3.

FIG. 6 is an interior view of the operator input device shown in FIG. 3.

FIG. 7 is an exploded view of the operator input device shown in FIG. 6.

FIG. 8 is a perspective view of the handle portion of the input deviceof FIG. 3.

FIG. 9 is a perspective view of the handle portion of the input deviceof FIG. 3 with some exterior components removed.

FIG. 10 is a perspective view of the handle portion of the input deviceof FIG. 3 with additional exterior components removed.

FIG. 11 is a perspective view of electronic components in the linkportion of the input device of FIG. 3.

FIG. 12 is a perspective view of electronic components in the linkportion of the input device of FIG. 3 with some exterior componentsremoved.

FIG. 13 is a perspective view of electronic components in the linkportion of the input device of FIG. 3 with additional exteriorcomponents removed.

FIG. 14 is a cross-section view of a portion of the input device of FIG.3 taken through the axis of rotation of the handle portion.

FIG. 15 is a block diagram showing electrical, magnetic, and opticalconnections of the input device of FIG. 3.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth.However, it is understood that embodiments of the invention may bepracticed without these specific details. In other instances, well-knowndevices, structures and techniques have not been shown in detail inorder not to obscure the understanding of this description.

Referring to FIG. 1 of the drawings, a master control workstation orsurgeon's console of a minimally invasive telesurgical system isgenerally indicated by reference numeral 100. The workstation 100includes a viewer 214 (shown in FIG. 2) where an image of a surgicalsite is displayed in use. A support 104 is provided on which an operator102, typically a surgeon, can rest his or her forearms while grippingtwo master controls 210, 212 (shown in FIG. 2), one in each hand. Themaster controls are positioned in a workspace 106 disposed inwardlybeyond the support 104. When using the workstation 100, the surgeon 102typically sits in a chair in front of the workstation, positions his orher eyes in front of the viewer and grips the master controls 210, 212one in each hand while resting his or her forearms on the support 104.

FIG. 1 also shows a patient side cart or surgical manipulator system 200of the telesurgical system. In use, the cart is positioned close to apatient for surgery, and it is then normally caused to remain stationaryuntil the surgical procedure has been completed. Manipulator system 200typically includes robotic arm assemblies 206. One of the robotic armassemblies is arranged to hold an image capturing device, e.g., anendoscope 202, or the like, which is coupled to the display of theworkstation. Each of the other arm assemblies 206 may include a surgicaltool 204 having a surgical end effector for treating tissue.

The robotic arms 206 will move and articulate the surgical tools 204 inresponse to the motions of the master controls 210, 212 at theworkstation 100, so that the surgeon 102 can direct surgical proceduresat internal surgical sites through minimally invasive surgicalapertures. The workstation 100 is typically used within an operatingroom with the cart 200, but it can be positioned remotely from the cart,even miles away.

Referring now to FIGS. 3 and 4, each master controller 210, 212 includesa four degree of freedom gimbal or wrist that allows rotation of anactuatable handle 12 about three axes—axis 1, axis 2, and axis 3 in FIG.4.

In the embodiment of the invention shown, the handle 12 is coupled to afirst elbow-shaped link 14 by a first rotatable joint 16 that permitscontinuous rotation of the handle. The first link 14 is coupled to asecond elbow-shaped link 18 by a second pivotal joint 20. The secondlink 18 is pivotally coupled to a third elbow-shaped link 22 by a thirdpivotal joint 24. The third link 22 is pivotally coupled to a platform(not shown) such that the third link can rotate with respect to theplatform about axis 4 to provide a fourth degree of rotational freedom.The fourth degree of rotational freedom is redundant but it allows thesecond and third links 18, 22 to be positioned to avoid interfering withthe operator's that is grasping the handle 12. The platform is supportedto provide three degrees of translational freedom. Thus each mastercontroller 210, 212 will generally allow movement of the handle 12within the workspace 106 with a plurality of degrees of freedom,typically with six degrees of freedom, three rotational degrees offreedom and three translational degrees of freedom. This allows theactuatable handle 12 to be moved to any position and any orientationwithin its range of motion.

The actuatable handle 12 includes grip actuators 28 and/or switches 30to allow the operator to actuate the surgical tool 204 being positionedby the motion of the handle. Finger loops 26 are attached to the handle12 to prevent the operator's fingers from slipping on the handle.

FIGS. 5 through 7, are views of components contained within theactuatable handle 12 and the first link 14. An important aspect of theinvention is that it provides continuous rotation of a roll input in acompact assembly suitable for use in an input device for a roboticsurgical instrument. Views with various components omitted are providedto allow the different elements of an embodiment of the invention to beseen. FIG. 5 shows the outer portion of the first link 14 cut away sothat the components contained within the first link can be seen. FIG. 6shows the components contained within the first link. FIG. 7 shows thecomponents in an exploded view, with some components omitted to allowcertain aspects to be seen more clearly.

Referring to FIGS. 5 through 7, the first link 14 is a hollow structurethat encloses mechanical components and electronics that support theactuatable handle 12. The hollow structure of the first link 14 is oftwo or more parts to facilitate assembly of the first link and thecomponents contained therein. The first link 14 includes bulkheadstructures 64, 66 to which internal components are attached.

The actuatable handle 12 includes a structure 16 that supports one ormore operator inputs such as switches 30 and grip controllers 28. Theoperator inputs may provide on/off control or a continuous range ofcontrol. For example, the grip controllers 28 may provide a range ofinput values that allows the surgical tool 204 to be moved betweenopened and closed positions by tracking the position of the gripcontrollers 28. A switch may have two or more positions to provideeither on/off input or a selection based on the switch position. Acontinuous input may be used to provide on/off control or a discretenumber of selections.

The support structure 16 is coupled to a shaft 46 that rotates withinone or more bearings 52, 54. The shaft 46 also supports electroniccomponents 50 that couple the input signals from the grip actuators 28and/or switches 30 to the master control workstation as will describedmore fully below. The bearings 52, 54 are supported by the bulkheadstructures 64, 66 of the first link 14 so that the actuatable handle 12rotates freely about a first axis 1 with respect to the first link.

Additional components may be fixed to the bulkhead structures 64, 66 ofthe first link 14. For example, a motor 36 is fixed to the first link14. The motor 36 is coupled to the handle 12 by beveled gears 38, 40.The motor 36 rotates the handle 12 about the first axis 1 to set anorientation of the handle to correspond to an orientation of thesurgical tool 204 and/or provide haptic feedback for the rotationalforce being applied. To sense an angular position of the handle 12 aboutthe first axis 1, an encoder and/or a potentiometer is coupled to themotor 36. Electronic components 42, 56, 48 are fixed to the bulkheadstructures 44, 64 of the first link 14 and coupled to the input signalsfrom the electronic components 50 that are rotatably supported by theactuatable handle 12 as will described more fully below.

Referring now to FIGS. 8 through 10, components contained within theactuatable handle 12 are assembled and supported such that thesecomponents rotate as a unit about axis 1, the axis of rotation for thehandle. A support structure 70, fixed to the end of the shaft 46,supports the electronic components 50 that receive the input signalsfrom the grip actuators 28 and/or switches 30. As best seen in FIGS. 9and 10, in which some of the outer structures are not shown, the gripactuators 28 and/or switches 30 are electrically coupled to electronics82 that condition and/or encode the operator input as electricalsignals.

The operator input signals are electrically coupled to signal generatorelectronics 78, 82 that generate a signal that is provided to an opticaldata transmitter 84 to optically transmit an encoded representation ofthe operator input. A rotary pot core half 76 is fixed to the handle 12by the electronic component support structure 70, which is fixed to theend of the shaft 46. The rotary pot core half 76 has an open face, anopposing closed face, and an axial passage 72 between the open face andthe closed face. A secondary transformer winding 74 is mounted in therotary pot core half 76. The secondary transformer winding 74 provideselectric power to the electronics 78, 82. The optical signal from theoptical data transmitter 84 is directed through the axial passage 72 ofthe rotary pot core half 76. The cable 80 that connects the electronicspasses through an axial opening in the shaft 46 that rotatably supportsthe handle 12.

Referring now to FIGS. 11 through 13, components contained within thefirst link 14 are assembled and supported such that these components arefixed with respect to the first link. A support structure 44 fixeselectronic components 56 to the bulkhead 64 of the first link 14.Additional electronic components are electrically coupled by a cable 86and directly fixed to the bulkhead 64 of the first link 14.

As best seen in FIG. 12, a stationary pot core half 88 is fixed to thesupport structure 44 with the electronic components 56. The stationarypot core half 88 has an open face, an opposing closed face, and an axialpassage 92 between the open face and the closed face. A primarytransformer winding 90 is mounted in the stationary pot core half andconnected to an electric power source (not shown). An optical datareceiver 94 (FIG. 13) is supported adjacent the closed face of thestationary pot core half 88.

FIG. 14 shows a cross-section of a portion of the input device takenalong axis 1 of the handle 12. The optical data transmitter 84 and theoptical data receiver 94 are aligned such that the optical data istransmitted substantially along the axis of rotation of the handle 12through the passages 92, 72 in the stationary and rotary pot core halves88, 76. The primary and secondary windings 90, 74 form a rotarytransformer. The stationary and rotary pot core halves 88, 76 are alsopart of the rotary transformer to increase the efficiency of thetransformer.

The stationary and rotary pot core halves 88, 76 are coaxial andconcentric with the axis of rotation of the handle 12. The primary andsecondary windings 90, 74 of the rotary transformer are configured sothat rotation of the secondary winding by rotation of the handle doesnot affect the operation of the transformer that they form. The openfaces of the pot core halves face one another and the primary andsecondary transformer windings 90, 74 are in close proximity so that aswitched current in the primary winding is magnetically coupled to thesecondary winding.

FIG. 15 is a block diagram showing electrical, magnetic, and opticalconnections of the input device. Components that are fixed to thesupport structure, which are shown to the left of the vertical dashedline, are not physically connected to components that are fixed to thehandle, which are shown to the right of the vertical dashed line. Thevertical dashed line represents an air gap in the rotary joint thatcouples the handle to the support structure. By eliminating a physicalconnection between the components in the support structure and thehandle, the handle is made freely rotatable.

A power source 100 is connected to the primary winding 90 of the rotarytransformer. The power source 100 and the primary winding 90 are fixedto the support structure. The primary winding 90 is magnetically coupled102 to the secondary winding 74 of the rotary transformer. The secondarywinding 74 is coupled to the power supply 104. The secondary winding 74and the power supply 104 are fixed to the handle. The power supplyprovides power 108 for the signal generator 116 and the opticaltransmitter 84 and may also power other devices fixed to the handle.

The operator inputs 118 are coupled to the signal generator 116 togenerate an encoded digital signal that represents the operator input. Apower sensing signal 110 is also connected to the signal generator 116so that the encoded digital signal also includes a representation of thevoltage being provided by the power supply 104. The optical transmitter84 optically transmits 114 the encoded digital signal to the opticalreceiver 94 that is fixed to the support structure.

A data processor 112 receives the encoded digital signal from theoptical receiver 94 and processes the signal to provide the encodedinformation to the robotic surgical system. The data processor 112provides a decoded representation 106 of the power sensing signal 110 tothe power source 100. The power source adjusts the electrical powerprovided to the primary winding 90 of the rotary transformer accordingto the decoded representation 106 of the power sensing signal 110.

Embodiments of the invention provide an input device for roboticsurgical techniques. The input device has a rotatable handle supportingoperator input devices. Data from the operator inputs is transmittedoptically across a freely rotatable joint by a rotary transformer.Electrical power form a power source is magnetically coupled to theoptical data transmitter in the freely rotatable handle. Data from thepower supply in the rotatable handle is transmitted optically to thepower source to provide closed loop control of the power supply in thefreely rotatable handle. The optical data path is along the axis ofrotation of the rotary transformer to provide a compact assemblysuitable for delicate operator inputs from the surgeon controlling therobotic surgical system.

While certain exemplary embodiments have been described and shown in theaccompanying drawings, it is to be understood that such embodiments aremerely illustrative of and not restrictive on the broad invention, andthat this invention is not limited to the specific constructions andarrangements shown and described, since various other modifications mayoccur to those of ordinary skill in the art. The description is thus tobe regarded as illustrative instead of limiting.

What is claimed is:
 1. An operator input device comprising: a supportstructure; a rotary transformer having a primary winding fixed to thesupport structure and electrically connected to an electric powersource, a secondary winding rotatably supported by the supportstructure, and an axial passage through the primary and secondarywindings; an optical data transmitter connected to the secondarywinding, the optical data transmitter rotatably supported by the supportstructure and aligned to transmit data through the axial passage in therotary transformer; an optical data receiver fixed to the supportstructure and aligned to receive data from the optical data transmitter;a signal generator rotatably supported by the support structure andelectrically connected to the secondary transformer winding and to theoptical data transmitter, the signal generator receiving power from thesecondary transformer winding and generating data to be transmitted bythe optical data transmitter; a bearing supported by the supportstructure; a tube rotatably supported by the bearing, the tube having aproximal end connected to the signal generator and a distal endconnected to the secondary winding; and a wire that electricallyconnects the signal generator to the secondary winding, the wire passingthrough the tube from the proximal end to the distal end.
 2. The inputdevice of claim 1, wherein the signal generator generates a voltagesignal to be transmitted by the optical data transmitter in response tothe voltage provided by the secondary transformer winding.
 3. The inputdevice of claim 2, wherein the power source is connected to the opticaldata receiver, the power source being turned on and off in response tothe voltage signal received by the optical data receiver.
 4. The inputdevice of claim 1, wherein the rotary transformer further includes a potcore, the primary winding being fixed in a first half of the pot corethat is fixed to the support structure, the secondary winding beingfixed in a second half of the pot core that is rotatably supported bythe support structure, and the pot core providing the axial passagethrough the primary and secondary windings.
 5. A method of providingdata from a rotatable source, the method comprising: generating datawith a signal generator that is rotatably supported by a supportstructure; coupling an electrical power source between a primary coiland a secondary coil, the primary coil fixedly supported by a supportstructure and connected to the electrical power source, the secondarycoil rotatably supported by the support structure and connected toprovide power to the signal generator; optically transmitting data fromthe signal generator to an optical data receiver with an optical datatransmitter, the optical data receiver fixed on the support structure,the optical data transmitter fixed on the secondary coil, the opticaltransmission directed through an axial passage through the primary andsecondary coils; generating a voltage signal in response to a voltageprovided by the secondary coil; and multiplexing the voltage signal withthe data from the signal generator.
 6. The method of claim 5, furthercomprising turning the electrical power source on and off in response tothe voltage signal received by the optical data receiver.
 7. A devicefor providing data from a rotatable source, the device comprising: meansfor generating data, the data generating means rotatably supported by asupport structure; means for receiving electrical power, the electricalpower receiving means rotatably supported by the support structure andconnected to the data generating means; means for optically transmittingdata, the optically transmitting means fixed on and connected to theelectrical power receiving means, the optically transmitting meanshaving an optical path directed through an axial passage toward a meansfor receiving optical data fixed on the support structure; means forgenerating a voltage signal in response to a voltage provided by theelectrical power receiving means; and means for multiplexing the voltagesignal with data generated by the data generating means.
 8. The deviceof claim 7, further comprising means for turning an electrical powersource on and off in response to the voltage signal received by themeans for receiving optical data.
 9. An input device comprising: asupport structure; a stationary pot core half fixed to the supportstructure and holding a primary transformer winding connected to anelectric power source, the stationary pot core half having a first axialpassage; an optical data receiver fixed to the support structureadjacent the stationary pot core half; a rotating structure that isrotatably supported by the support structure and is rotatable about anaxis of rotation; a rotary pot core half fixed to the rotating structurefacing the stationary pot core half and holding a secondary transformerwinding, the rotary pot core half having a second axial passage; asignal generator fixed to the rotating structure and connected to thesecondary transformer winding; an optical data transmitter fixed to therotating structure on the axis of rotation, the optical data transmitterconnected to the secondary transformer winding to receive power and tothe signal generator to transmit data from the signal generator throughthe first and second axial passages to the optical data receiver; asignal generator fixed to the rotating structure and electricallyconnected to the secondary transformer winding and to the optical datatransmitter, the signal generator receiving power from the secondarytransformer winding and generating data to be transmitted by the opticaldata transmitter; a tube rotatably supported by the support structure, aproximal end of the tube connected to the signal generator and a distalend of the tube connected to the rotary pot core half; and a wire thatelectrically connects the signal generator to the secondary transformerwinding, the wire passing through the tube from the proximal end to thedistal end.
 10. The input device of claim 9, wherein the signalgenerator generates a voltage signal to be transmitted by the opticaldata transmitter in response to the voltage provided by the secondarytransformer winding.
 11. The input device of claim 10, wherein theelectric power source is connected to the optical data receiver, theelectric power source being turned on and off in response to the voltagesignal received by the optical data receiver.